Roof Rack Service Bulletin Source?

[RV8Pilot]

I'm going to install my GM roof rack myself, and see from other posts that there is a service bulletin, NHTSA # SB623775, that relates to "Roof Rack Installation Instructions."
Anyone know how I can get the text of that SB?
Thanks...

 

[gandolphxx]

I don't have the TSB, someone will post it, but can tell you a couple things to watch out for:

1. Don't let any of the drillings get trapped in the rubber molding ofer the doors - big rust problems.

2. Be careful when drilling the holes, don't go too deep or you will go into the headliner.

 

[wrchism]

I was glad to watch my Av decend off of the transporter with roof rack in place - factory installed - no rust, no drips, no errors!

But, given the choice between doing it myself and letting the dealer do it, I might let the dealer do it. If they screw up, they'll repaint for you. If you slip with the drill, the repaint will be on you! Generally 'do-it-yourself' is my choice, but drilling on a slippery painted surface sounds tricky.

If you do it yourself, as they say "measure twice and drill once - the other way around isn't pretty, and use a good centerpunch and sharp bit!

 

[ygmn]

I heard it took a special tool to install the rack.well my dealer told me so when I went in to get it installed last year. Tell me how it goes when done as mine is still in the box.

 

[RV8Pilot]

I don't have the TSB, someone will post it, but can tell you a couple things to watch out for:

1. Don't let any of the drillings get trapped in the rubber molding ofer the doors - big rust problems.

2. Be careful when drilling the holes, don't go too deep or you will go into the headliner.

They mention vacuuming up the mess, and also say to use a drill stop set to 1/2" to prevent hitting the headliner. I think I'll start at 3/8" or so just to be safe.

If you do it yourself, as they say "measure twice and drill once - the other way around isn't pretty, and use a good centerpunch and sharp bit!

The kit actually comes with a nice sharp new drill bit. You pilot hole with your own 1/8" drill bit, then use theirs for the final hole. It also has a full size template to lay out the holes. Don't have to measure anything actually. The template seems to fit along the edge of the roof, from front to back. Just tape it down, mark the hole locations, and have at it

I heard it took a special tool to install the rack.well my dealer told me so when I went in to get it installed last year. Tell me how it goes when done as mine is still in the box.

It does use a special tool, also included in the kit. They use welnuts as screw anchors to hold the rack to the roof. A welnut works like a pop rivet, except instead of pulling a stem to set the blind side, you put a bolt into the welnut and by turning it pull up the blind side of the welnut. Of course the welnut wants to turn with the bolt, so thats where the special tool comes in. It's just a bolt that fits through a sleeve. When you insert the bolt into the welnut, the sleeve keeps the welnut from turning as you turn the bolt. The bolt pulls the welnut up from the bottom (underside of the roof). When it's set, you remove the bolt/sleeve and you are left with a bolthole in your roof! The welnuts have a bead of permatex-type goop under the head, to help seal the opening.

The kit did not supply the rust inhibitor for the now bare metal edges of the roof after drilling, but did call for some in the instructions. I'm going to my Chevy dealer to ask what they use. If it only comes in gallons, I have some self etching primer/sealer that I'll use. I also plan on using permatex in the mounting screw holes just before installation just to be safe.

The only other thing the kit did not include was the guts to actually take a drill to my new Av

 

[ygmn]

GO for it!!!!!..........but remember this you did pay for the installation if it was included with your AV when you bought it.

 

[shafman1]

I wish you luck. I'm sure you can do it, but I would think by now that the dealers are able to do it after being retrained on their mistakes.

 

[RV8Pilot]

GO for it!!!!!..........but remember this you did pay for the installation if it was included with your AV when you bought it.

Actually, the roof rack didn't cost me anything. We (me, my wife, and the dealer) came to terms for price based on a dollar figure under invoice. I like to do it that way, so I can go ahead and pick any car on the lot and don't have to re-negotiate for every difference in options.
Anyway, we were down to two, green and red, neither of which had a roof rack. I said to the salesman "if the red one had a roofrack in the back seat, I'd take it. Five minutes later here he comes with a long box. He opens the tailgate and slides it in. It did not show up on the invoice, so I essentially got it for the asking. I called a local shop that works with my dealer and he wanted $150 to install it. Since I have more time than money, and less brains than either I decided to look into doing it myself.
Sorry to be so wordy, but you're right. I'd be nuts to pay for it, and then say "nah...don't bother installing it...I always wanted to drill 16 holes in the roof of my new truck...
So next week I may get up the courage to do the deed...

 

[RV8Pilot]

I wish you luck. ?I'm sure you can do it, but I would think by now that the dealers are able to do it after being retrained on their mistakes. ?

I agree...I think they would do a proper job. I did ask the salesman at the time if I could install it myself, and his opinion was that they would never ask if I did it or not. That's when he told me the name of the local shop they use for mods and owner purchased upgrades. Not a GM shop, just a local garage that the dealer uses. I figure if I screw it up right at the start, dent the roof, make an oval hole, etc. I'll just have to own up to it and pay for the repair. If I do an acceptable installation, according to factory instructions, I figure it's under warranty

 

[1struck]

I did it myself - real easy, just tape the weather strip down to prevent metal chips from getting behind. Went to two dealers for rust inhibitor to put on edges of the holes. They both recommended the same stuff - not the GM material but aftermarket Rustop. Went on whitish, turned dark. An hour later I brushed some blue enamel around the edge of the hole and let dry. Next day 16 welnuts and the rest is history. Just make sure you use a little lubrication on the tool just like it says or you won't get them tight enough ( they want to spin with the tool spacer) . The good thing about those is unlike pop rivets, you can always go back and snug em up a little bit more - just in case.

 

[Blue_Lagoon]

The day that I picked my Av up. I opened the tailgate and noticed a box. The dealer and I opened the box and much to our suprise was a roof rack. The dealer said it must have come with the truck (dealer trade) and its all yours. Now the debate on whether or not to insall it. It has been in the bed of the truck for a month now. Still can't decide.

 

[GoldBowTie]

Regardless of who does the install, check under the rubber molding above the door for drill shavings.

I found rust under mine this weekend.

My rack was dealer installed in October and the chips had all winter to "ferment."

 

[RV8Pilot]

I did it myself - real easy, just tape the weather strip down to prevent metal chips from getting behind. ?Went to two dealers for rust inhibitor to put on edges of the holes. ?They both recommended the same stuff - not the GM material but aftermarket Rustop. ?Went on whitish, turned dark. ?An hour later I brushed some blue enamel around the edge of the hole and let dry. ?Next day 16 welnuts and the rest is history. ?Just make sure you use a little lubrication on the tool just like it says or you won't get them tight enough ( they want to spin with the tool spacer) . ?The good thing about those is unlike pop rivets, you can always go back and snug em up a little bit more - just in case.

Glad it went well. Where did you get your Rustop? I found a place (actually, Gandolphxx sent me a web site) but they may only sell to shops. I'm going to call them tomorrow and find out. Do you know of any acceptable substitutions? I was going to dip the welnuts in some self-etching primer, and install them wet but if there's something better now's the time for me to find out about it...

 

[1struck]

I got mine from the dealer - they let me 'borrow' theirs since you only need a little bit. They purchase it at a NAPA - Genuine Auto Parts store - Service manager said any rust converter should do. When I questioned them on there not being any rust to convert - he said they had been using it for years - never had a problem. They don't use the GM stuff because you have to order it by the case and nobody ever buys it

 

[RV8Pilot]

The day that I picked my Av up. I opened the tailgate and noticed a box. The dealer and I opened the box and much to our suprise was a roof rack. ? The dealer said it must have come with the truck (dealer trade) and its all yours. Now ?the debate on whether or not to insall it. It has been in the bed of the truck for a month now. Still can't decide.

Hey Blue_Lagoon, you still thinking about installing the roof rack? Is anyone still reading this thread? I just got back from vacation...I installed the rack before I left and took some pictures but didn't have the time to post anything. If anyone wants the blow-by-blow account of my roof rack installation, let me know and I'll figure out how to post pictures here and share my experience. There are a few tips that I could pass along if anyone is interested.
Sorry to have left the thread for so long...